Maxon TE-15 Operation Manual

To find maintenance & parts information for your TE-15, TE-20, TE-25 or TE-30 Liftgate, go to www.maxonlift.com. Click the PRODUCTS, TUK-A- WAY & TE-15/TE-20, TE-25/TE-30 buttons. Open the Maintenance Manual in the PRODUCT DOCUMENTATION window. For parts, click on the PARTS PORTAL, TUK-A-WAY & TE-15/TE-20, TE-25/TE-30 buttons.

SUMMARY OF CHANGES: M-16-34 REV A ..........................4 WARNINGS ............................................................................5 LIFTGATE TERMINOLOGY ...................................................6 RECOMMENDED DAILY OPERATION CHECKS .................8 DECALS .................................................................................11 FORKLIFT ADVISORY ..........................................................13 ROADSIDE OPERATION ADVISORY ...................................14 OPERATION ..........................................................................15 USING CART STOPS (IF EQUIPPED) ..................................22

COVER Updated REV, date of release, cover image and Maxon website information. 6 Added TE-15 & TE-20 terminology page. SUMMARY OF CHANGES: M-16-34 REV A

injury. Comply with WARNINGS and Liftgate operating instructions in this manual. Do not allow untrained persons or children to operate the Liftgate. If you need to replace an Operation Manual, additional copies are available from: MAXON Lift Corp. 11921 Slauson Ave Santa Fe Springs, CA 90670 (800) 227-4116 WARNING ! NOTE: For latest version manuals (and replacements), down- load manuals from Maxon’s website at www.maxonlift.com. 2. Do not exceed rated load capacity of the Liftgate which is 1500 LB for model TE-15, 2000 LB for TE-20, 2500 LB for TE-25 and 3000 LB for model TE-30. 3. Do not allow any part of your body to be placed under, within, or around any portion of the moving Liftgate or its mechanisms, or in � a�position�that�would�trap�them�between�the�platform�and�the�floor� of truck body (or between platform and the ground) when Liftgate is operated. 4. Consider the safety and location of bystanders and location of nearby objects when operating the Liftgate. Stand to one side of platform while operating the Liftgate. Be certain that the area the Liftgate will move through during operation is clear of all obstacles. 5. Comply with all attached instruction decals and warning decals. 11. Above all, USE GOOD COMMON SENSE when operating this Liftgate. 8. Do not move vehicle unless Liftgate is correctly stowed. 6. Keep decals clean and legible. If decals are illegible or missing, have them replaced. Get free replacement decals from Maxon. 7. Never drive a forklift on the Liftgate platform. 10. A correctly installed Liftgate will operate smoothly and reasonably quiet. The only noticeable noise, during Liftgate operation, is from the power unit while the platform is raised. Listen for scraping, grating and binding noises and have the problem corrected before continuing to operate the Liftgate. 9. Correctly stow platform when not in use. Extended platforms could create a hazard for people and vehicles passing by. 12. Never use a cell phone while operating the Liftgate.

CONTROL SWITCH PUMP BOX DUAL STEP LIFT CYLINDER MAIN FRAME LIFT FRAME WEDGE FLIPOVER PLATFORM PARALLEL ARM PLATFORM OPENER DOCK BUMPER EXTENSION PLATE TORSION SPRING

EXTENSION PLATE LIFT FRAME CONTROL SWITCH PARALLEL ARM PLATFORM LIFT CYLINDER PUMP BOX MAIN FRAME WEDGE FLIPOVER PLATFORM OPENER DOCK BUMPER FLEX STEP TORSION SPRING

 Make sure vehicle battery is fully charged and battery terminal connec- tions are clean and tight.  Visually check that pump cover is bolted on securely and undamaged. Look�for�hydraulic�fluid�leaking�from�the�pump�box. Before operating the Liftgate, the operator should do the following:  Visually check that control switch is in place and undamaged. Use the operation instructions in this manual to lower the Liftgate to the ground and open the platform and flipover.  Check main frame, lift arms, parallel arms and platform openers for cracks and bends. Make sure rollers, on the platform openers, roll freely. Also, make sure all bolts and pins are in place and undamaged.  Visually check for cracks and bends on the extension plate. Also, make sure fasteners are in place and undamaged and extension plate is clean (no oil, debris, or corrosion).  Check the hydraulic cylinders for leaking seals and hose connections. Follow the hydraulic hoses (or return lines for gravity down Liftgates) from the cylinders to pump box. Make sure all hoses are connected at both�ends�and�there�are�no�cracks,�chafing,�and�fluid�leaks.  Make sure main frame, lift arms, parallel arms and platform openers are clean (no oil, debris, or corrosion).  Visually check that all decals are in place (see DECALS page). Also, make sure decals are legible, clean, and undamaged. NOTE:�Before�you�check�the�Liftgate,�park�vehicle�on�flat� ground and set the parking brake. NOTE: If any of the following operation checks reveal a need to service or repair Liftgate, do not operate the�Liftgate�until�a�qualified�mechanic�services�or� repairs the Liftgate.

bed height and no load on platform, outboard edge of platform must be higher than extension plate as shown in the YES illus- tration (FIG. 9-1). If the platform is tilted up like the YES illustration, you can operate Liftgate. If platform is level at bed height like the NO illustration (FIG. 9-2), do not operate the Liftgate. (See NOTE at beginning of the DAILY OPERATION CHECKS.) PLATFORM AT BED HEIGHT FIG. 9-1 NO PLATFORM AT BED HEIGHT FIG. 9-2 YES LEVEL LINE LEVEL LINE

coil springs, and fasteners are in place and undamaged.  �Make�sure�platform�and�flipover�load-carrying�surfaces�are�clean�(no� oil, debris, or corrosion). Use the operation instructions in this manual to operate the Liftgate through one cycle without a load on the platform. RAISE the platform to vehicle bed height. Next, lower the platform to ground level.  When the Liftgate is moving, listen for unusual noises and look for jerk- ing motion or uneven movement on either side of the platform. If service or repairs are not required (or if completed), stow the Lift- gate. RECOMMENDED DAILY OPERATION CHECKS - Continued  With the platform unfolded and on the ground, check if the shackles and the tip of platform touch the ground at the same time as shown in the YES illus- tration (FIG. 10-1). If the platform looks like the YES illustra- tion, you can operate Liftgate. If the tip of the platform is off the ground and platform looks like the NO illustration (FIG. 10-2), or if the shackles are off the ground, do not operate the Liftgate. (See NOTE at begin- ning of the DAILY OPERATION CHECKS.) PLATFORM UNFOLDED ON THE GROUND FIG. 10-1 TIP OF FLIPOVER LEVEL GROUND YES SHACKLE NO LEVEL GROUND TIP OF FLIPOVER SHACKLE PLATFORM TIP OFF THE GROUND FIG. 10-2

attached at the factory. If vehicle does not permit this layout, decals in the manual and decal kit must be applied so that they are easily visible when approaching vehicle to operate Liftgate. Use good common sense when locating these decals on vehicle. DECALS NOTE: Ensure there is no residue, dirt or corrosion where decals are attached. If necessary, clean surface before attaching decals. CAPACITY DECAL SEE TABLE 11-1 STOW WARNING DECAL P/N 282847-02 FIG. 11-1 DECAL “A” DECAL “F” DECAL “C” DECAL “B” WARNING DECAL P/N 265736-03 INSTRUCTION DECAL P/N 285800-01 MODEL DECAL P/N CAPACITY DECAL TE-15 220386 1500 POUNDS TE-20 220387 2000 POUNDS TE-25 220382 2500 POUNDS TE-30 220388 3000 POUNDS TABLE 11-1

increases the chance of personal injury and damage to Liftgate, cargo & vehicle. Making the loading area more visible to passing traffic can help reduce the chance of injury and damage. WARNING ! ROADSIDE OPERATION ADVISORY NOTE: MAXON�recommends�placing�at�least�2�traffic�cones�on�the� traffic�side�of�the�platform�loading�area�as�illustrated�below.� Remove cones after platform is stowed and before moving the vehicle. VEHICLE TRAFFIC APPROACHING FROM THIS SIDE TRAFFIC CONES POSITIONED BY PLATFORM LOADING AREA FIG. 14-1

platform and flipover. Always use handle on side of flipover to unfold (and fold) flipover. Holding the flipover any other way can create a hazard and injure operator. WARNING ! PRESSURIZING HYDRAULIC SYSTEM FIG. 15-1 OPERATION 2. Pull handle to release safety hook (FIG. 15-2B) while pushing the toggle switch to DOWN position (FIG. 15-2A) until shack- les touch the ground. FIG. 15-1A 1. Standing to the side of platform (FIG. 15-1), pressurize hydraulic sys- tem by pushing the toggle switch to UP position for 2 seconds (FIG. 15-1A.) LOWERING PLATFORM FIG. 15-2 FIG. 15-2A FIG. 15-2B UP DOWN SHACKLE

unfold�the�flipover�as�fol- lows. If equipped with hook, press�down�on�the�flipover� and rotate hook away from the handle (FIGS. 16-2 and 16-2A). Then, use handle FIGS. 16-2 and 16-2B) to unfold�the�flipover. UNFOLDING FLIPOVER FIG.16-2 FIG. 16-2B 3. Use handle on bottom of platform (FIG. 16-1A) to unfold the platform and flipover�(FIG. 16-1). FIG. 16-1A UNFOLDING PLATFORM & FLIPOVER FIG. 16-1 FIG. 16-2A

RAISING & LOWERING PLATFORM FIG. 17-1 5. Raise the platform (FIG. 17-1) by pushing the toggle switch to the UP position (FIG. 17-1A). If loading (or unloading) the platform, wait a second before releasing the toggle switch, after platform reaches bed height. To lower the platform, push the toggle switch to the DOWN posi- tion (FIG. 17-1B). PLATFORM NOTE: While operating the Liftgate, release toggle switch to stop the platform. UP DOWN FIG. 17-1B FIG. 17-1A

level as shown in FIG. 18-1. LOADING PLATFORM AT GROUND LEVEL FIG. 18-1 7. Raise the platform to bed height (FIG. 18-2). Move the load off platform into vehicle (FIG. 18-2). UNLOADING PLATFORM AT BED HEIGHT FIG. 18-2 INBOARD EDGE PLATFORM VEHICLE BODY PLATFORM WARNING ! A load should never extend past the edges of the platform. Do not place unstable loads on platform and do not allow load to exceed the lifting capacity of the Liftgate. If standing on platform, do not allow your feet to extend beyond the inboard edge of the platform.

FIG. 19-1 PLATFORM 8. Load the platform at bed height (FIG. 19-1) as fol- lows. Push load out of the vehicle to correct position on the platform. Place all loads as close as possible to the inboard edge of the platform with heaviest part toward the truck body as shown in FIG. 19-1. If standing on platform with the load, stand in the footprint area shown and comply with the WARNING on previous page. Pulling the load from vehicle to platform can result in a fall from platform and serious injury. When unloading vehicle, always push the load out on the platform. WARNING ! VEHICLE BODY 9. Lower the platform to ground level (FIG. 19-2). Move load off the platform (FIG. 19-2). UNLOADING PLATFORM AT GROUND LEVEL FIG. 19-2 PLATFORM INBOARD EDGE OPERATION - Continued

fold�the�flipover. 11.�Fold�flipover�on�the�platform� using�handle�on�the�flipover� (FIG. 20-2A). If equipped, hook the platform to handle on�flipover�(FIG. 20-2B). FOLDING FLIPOVER ON PLATFORM FIG. 20-2 FIG. 20-2A 10. Before moving the vehicle, prepare the Liftgate as follows. Make sure load is removed from platform. If the platform is at bed height, push the toggle switch to the DOWN position as shown in FIG. 20-1A. Release toggle switch when platform 2” off the ground (FIG. 20-1). PLATFORM 2” OFF THE GROUND FIG. 20-1 FIG. 20-1A Never move the vehicle unless the Liftgate is properly stowed. WARNING ! FIG. 20-2B

21-2) by pushing the tog- gle switch to the UP posi- tion (FIG. 21-2A). Wait a second, after platform is stowed all the way, before releasing toggle switch. 14. Liftgate is ready for transport. CORRECTLY STOWED PLATFORM FIG. 21-2 FIG. 21-2A 12. Use handle on bottom of plat- form (FIG. 21-1A) to lift and fold�the�platform�and�flipover� (FIG. 21-1). FOLDING PLATFORM & FLIPOVER FIG. 21-1 FIG. 21-1A OPERATION - Continued

Cart stops prevent loaded carts from rolling off outboard end of platform. Single cart stops are 1 section, about the same as overall width of platform, and operate with one set of controls. Dual cart stops are 2 identical sections, with a com- bined width about the same as overall width of platform, and each is independently operated with separate controls (1 set of controls per cart stop). The following procedure shows dual cart stops. A single cart stop operates the same way. 1. At ground level, move load on platform with cart stops as shown in FIG. 22-1. To prevent injuries caused by tripping and falling, make sure cart stops are closed before walking on and off outboard end of platform. LOADING PLATFORM AT GROUND LEVEL (CART STOPS CLOSED) FIG. 22-1 NOTE:�Cart�stops�are�usually�closed�when�not�in�use.�If�you�find�the� carts stops are already open when rolling a load from the ground to the platform, you may roll the load over the cart stop. The cart stop will close temporarily as the load crosses and reopen when the load is off the cart stop. CART STOPS USING CART STOPS (IF EQUIPPED)

FIG. 23-1A 2. Open cart stops (FIGS. 23-1A and 23-1B). Next, position cart and stand in the footprint area as shown in FIG. 23-1A. NOTE: Cart stops are opened by rotating the hook (FIG. 23-1B). UNLOADING PLATFORM AT BED LEVEL (DUAL CART STOPS OPEN) FIG. 23-2 3. Raise the platform to bed level (FIG. 23-2). Move the load off the platform into the vehicle body (FIG. 23-2). CART STOPS OPENING CART STOPS (RH SIDE OF FLIP OVER) FIG. 23-1B ROTATE TO OPEN HOOK VEHICLE BODY PLATFORM USING CART STOPS (IF EQUIPPED) - Continued

at bed level, make sure cart stops are open (FIG. 24-1). Push load out of the vehicle to correct position on the platform. Place all loads as close as possible to the inboard edge of the platform with heaviest part toward the vehicle body as shown in FIG. 24-1. If standing on platform with the load, stand in the footprint area shown and comply with the WARNING on page 18. Pulling the load from vehicle to platform can result in a fall from platform and serious injury. When unloading vehicle, always push the load out on the platform. WARNING ! CART STOPS CLOSED FIG. 24-2 5. Unload platform with cart stop at ground level as shown in FIG. 24-2. Make sure cart stop is closed before mov- ing load off the platform. To close, push the cart stop and hook in place (FIG. 24-3). CLOSING CART STOPS (RH SIDE OF FLIPOVER) FIG. 24-3 6. Move load off the platform as shown in FIG. 24-2. NOTE: Cart stops are kept closed with a hook (FIG. 24-3). Make sure latch is locked. LOADING PLATFORM AT BED LEVEL (DUAL CART STOPS OPEN) FIG. 24-1 INBOARD EDGE VEHICLE BODY PLATFORM CART STOPS CART STOPS